Welding control apparatus



Jan. 7, 1947. H. PURAT WELDING CONTROL APPARATUS Filed Nov. 26, 1942 5 Sheets-Sheet 1 Q INVENTOR flu a fizz '42.. BY M ATTORNEYs.

Jan. 7, 1947. H, PURAT- 2,413,783

WELDING CONTROL APPARATUS F iled Nov. 26, 1942 5 Sheets-Sheet? v INVENTOR E 5 730122- ATTORNEY.

Jan. 7, 1947. PURAT- 2,413,783

WELDING C ONTROL APPARATUS Filed Nov. 26, 1942 5 Sheets-Sheet 4 [It zza 2 3i Jan. 7, 1947. H. PURAT 2,413,783

WELDING CONTROL APPARATUS Filed Nov. 26, 1942 5 Sheets-Sheet 5 Fatentecl Jan. 7, 1947 WELDING CONTROL APPARATUS Hugo Purat, Detroit, Mich,

assignor to Progressive Welder Company, Detroit, Mich., a corporation of Michigan Application November 26, 1942, Serial No. 466,981

6 Claims. 1

The present invention relates to methods of and apparatus for controlling the movements of and pressures applied to work engaging members of various types. As specifically disclosed herein, the invention provides improved methods of and apparatus for controlling the movements of and the pressures applied between the electrodes of a resistance welding machine.

The principal objects of the invention are to provide improved methods and apparatus, as aforesaid, which may be economically manufactured and installed, and which are efiicient and reliable in operation; to provide such arrangements utilizing combined pneumatic-hydraulic units associated together in such a way as to enable a desirably large range of movement of the electrodes from a retracted position to an initial work engaging position and to further enable the development of desirably higher welding pressures following such initial movement; to provide such arrangements in which one or more of the electrodes of the machine is provided with an actuating ram, disposed to be supplied through one hydraulic circuit with a hydraulic fluid to cause the movement of the electrode from a starting position to a work engaging position, and disposed to receive hydraulic pressure through another circuit to produce the actual welding pressure; to provide such arrangements in which both circuits are energized by combination pneumatichydraulic means and wherein at least one of the means is so arranged as to provide a succession of diiferent pressures during the actual welding period.

Further objects of the invention are to provide a resistance welding machine having a pair of opposed electrodes, both of which are movable relative to the frame of the machine and both of which are disposed to be actuated so as to apply desired welding pressure to work interposed between the two electrodes; to provide such arrangements wherein the actuating means for both electrodes is common thereto and wherein cooperating means are provided to insure the proper relation between the distances travelled by the respective electrodes in being brought into engagement with the work.

With the above as well as other and more detailed objects in view, which appear in the following description and in the appended claims, a preferred but illustrative embodiment of the invention is shown in the accompanying drawings, throughout the several views of which corresponding reference characters are used to designate corresponding parts and in which:

Figure 1 is a view in side elevation of a resistance welding machine embodying the invention;

Fig. 2 is an enlarged view in side elevation of the combination pneumatic-hydraulic mechanism for controlling the movement of the electrodes of the machine of Fig. 1;

Fig. 3 is a top plan view of in Fig. 2;

Fig. 4 is a view in longitudinal section of the dual booster unit employed in the structures of Figs. 2 and 3;

Fig. 5 is a fragmentary view in section of an equalizing valve which it is preferred to use with the invention;

Figs. 6, 7, 8, 8A and 8B are views, respectively, of solenoid operated valve mechanisms which may be and preferably are used in connection with the invention;

Fig. 9 is a more or less diagrammatic view of a double check valve, which may be used in connection with the invention;

Fig. 10 is a schematic diagram of penumatichydraulic circuits embodying the invention;

Fig. 11 is a diagrammatic view of electrical control circuits which may be utilized in the prac tice of the invention; and

Fig. 12 is a view showing the physical relation between the relay coils and contacts shown separated from each other in Fig. 11.

It will be appreciated from a compelte' understanding of the present invention that the improvements thereof may be utilized in connection with a wide variety of machines, intended for a corresponding variety of different uses. It is now preferred to utilize the invention to control the movements of the electrodes of resistance welding machines, and in an illustrative but not in a limiting sense, the invention is so disclosed herein.

Referring first to Fig. 1, the illustrated machine is of the vertically arranged press type and is provided with an enclosing frame structure it having forwardly projecting electrode supporting horns l2 and M, which support, respectively, the upper and lower electrodes 16 and IS. The main body of the frame I0 alfords space to accommodate the electrode control unit designated as a whole as 20, as well as for the usual welding transformer 22. The electrode It is electrically connected to one secondary terminal 24 of the transformer through a flexible bus bar 26, and the lower electrode i8 is similarly connected to the other secondary terminal 28, through a flexible bus bar 30. The holder 32 for the upper electrode is suitably guided for vertical reciprocating movements in bearings (not shown) provided the structure shown therefor at the frontof the horn 2. The horn 12 also carries a double acting hydraulic ram 35, the diagrammatically illustrated piston 38 whereof is connected, through its piston rod 38, to the electrode holder 32. The use of double acting rams for controlling electrode movements is conventional, and it is believed, therefore, that no further illustration is needed of the operative connection between the ram 36 and the electrode Hi.

The lower horn is similarly arranged to pro-. vide bearings for the holder 4! associated with the lower electrode l8, and this holder is coupled to the piston rod of a double acting hydraulic ram G2 in a manner similar to that described above.

The electrodes I 6 and i8 are relatively widely spaced when they occupy their illustrated re-v tracted or starting positions, thus permitting the necessary work to be readily interposed. therebetween. An important feature of the present invention resides in movably mounting both the upper and the lower electrodes. In thewelding of relatively heavy sections, it frequently becomes necessary to support the work in its movement into and out of the welding throat and all points of the work at which welds are to be made are not necessarily at the same elevation. By making both electrodes movable, these difierences in elevation do not require adjustments of the means for supporting the work, since allor any part of the necessary relative electrode movement can be imparted to either or both of the electrodes.

As will be understood, the pneumatic-hydraulic elements of the present system may be variously constructed andmay be variously positioned relative to each other, either in the machine or in part at least remotely from it. It is preferred, however, to build these elements, together with the operating valves therefor into the previously identified unitary structure, designated as a whole as 25, and positioned, as shown in Fig. 1, within the machine frame.

The unit 2%, as shown in more detail in Figs. 2 and 3, comprises a base 58, upon which a pair of cylinders 52. and 54 are mounted. The cylinders are disposed to be normally filled to sub,- stantially three-fourths their full capacity with a suitable hydraulic fluid, such as oil, and are provided with an equalizing connection 53, which connect the two adjacent the bases thereof. The equalizingconnection 53 includes a double checl; valve 55 of the ball type, which is shown in more detail in Fig. as comprising a tubular housing 58 into the opposite ends of which nipples 5B are threaded. The nipples 55 are provided with, aligned bores 52. A chamber 64 is defined by the area between the, inner ends of the nipples 55 and the wall of the housing 58, and this chamber receives a ball 65. It will be appreciated that if pressure is applied to the left-hand end of the valve 55, for example, the ball 55 is thereby seated against the end of the right-hand nipple E9 and closes off the passage therethrough. A pressure applied to the right-hand end of the valve, on the other hand, causes the ball 55 to seat against the end of the left-hand nipple til and close oif the passage therethrough. So long as the pressures applied to the two ends of the valve, however, are balanced or substantially so, the ball 56 occupies an intermediate position in which it permits a gradual interchange of fluid between the two cylinders 52 and; 5 The valve 56 and connection 53 thus serve, under normal inactive conditions, to equalize the levels of the oil in the two cylinders 52 and 54.

The cylinders 52 and 5t serve as a mount for a dual booster unit iii, which is shown in more detail in Fig. i, as comprising a generally cylin drical end portion 42, to the right-hand end whereof a cooperating cylinder member id is secured by means of circumferentially distrib uted studs '86. The right-hand end portion ll of the interior surface of the cylinder member i2 is suitably treated to slidably receive a piston 18. Piston i8 is provided with a piston rod which projects, into and constitutes the piston associated, with a hydraulic-cylinder ltd. The hydraulic cylinder ltd is defined by a sleeve received in aneck portion 82 which projects axially inwardly from the left-hand end of the cylinder member l2. A spring 84, seated between the end of the cylinder member 12 and piston 78, continuously urges the latter. towards the right to a position in which it seats against the end of the cooperating cylinder member i i.

The cooperating cylinder member is slidably receives a piston 85, the piston rod 88 whereof projects through thebase of the member it into abutting relation with the piston 18. A suitable elastic fluid such as air, for actuating the piston 18 may be introduced into the annular cylinder space 5% between the piston l8 and the end of the member is, through a nipple 92 and a pas sage M, which opens into the space 963. Similarly, a suitable elastic fluid, such as air, for the piston 88 may be introduced into the annular. cylinder space 95, throughothe nipple 98. As hereinafter described, the oil cylinder Hill. communicates, through suitable regulator valves with the rams 36 and t2, and the normal welding pressure is applied to these rams by admitting air to the cylinder space 96, thereby applying pressure to the oil in the cylinder lflil through the piston rods 88 and 85. The higher welding pressure is aiforded by additionally admitting air to the annular space 95, thus proportionately increasing the unit pressure applied to the oil in the cylinder I50.

On the other hand, the movements of the rams 34 and 52, so as to. bring the electrodes l5 and I8 into engagementwith the, work, are effected by admitting air to the upper part of the cylinder 5a through the air inlet line 152. This action circulates oil from the cylinder 54 throughcthc hereinafter described control valveinto the, electrode rams 3G and 42, and in view of the materially greater oil capacity of the cylinder 54, as compared to the cylinder I65, it will be appreciated that a substantial amount of electrode movement can thus beprovided. The return movement of the electrodes from the welding position to the position illustrated inl-iig. l is effected by admitting air to the cylinder 52, through its inlet connection I04, whichv action, as hereinafter described; actuates the electrode rams 3d and 42 in the opposite direction.

The valving of the system is controlled by a four-way valve E55, which controls the application to and exhaustion of, air from the cylinders 52 and 56; a three-wayvalve "18, which controls the application toand exhaustion of air from 1e welding. pressure cylinder 96; a; three-way valve llll'which controls the application to and. exhaustion of pressure from the forging pressure cylinder a threeeway valve I [2 which controls the inlet line associated with the'valve H36; a. pair of regulator valves H4 and H6 associated,

respectively, with the electrode rams 34 and 42;

a pair of regulator valves H8 and I20 associated, respectively, with the valves I08 and III), and which serve, consequently, to determine the values of the welding and forging pressures; a twoway hydraulic valve I22, which serves to isolate the electrode rams 32 and 32 from the cylinder 52 at the conclusion of the feed movements of the electrodes; and a two-way check valve I24 associated with the upper electrode ram 34, and which serves to maintain sufficient pressure in this ram during inactive periods of the machine to maintain upper electrode It in its elevated position. The valves I55, I38, H6, H2 and 522 may be and preferably are located immediately adjacent the unit 2! as shown in Figs. 2 and 3, and may, a will b understood, be supported by the associated piping. The two regulator valves H8 and I20, which determine the welding and forging pressures, respectively, are preferably carried by the upper horn. I2 of the machin and are provided with exposed operatin handles, by which these pressures maybe conveniently adjusted. Suitable gauges H9 and I2! may, as will be understood, b located adjacent these valves to afford an indication of the various pressure settings. The regulator valves IM and IIS are preferably located immediately adjacent the associated rams 34 and 42 as is shown in Fig. 1. The check valve I24 may be and preferably is located immediately adjacent the ram 34 so as to enable its ready adjustment. 1

As will be understood, the above identified valves may be variously constructed, illustrative constructions being shown in Figs. 6, '7, 8, 8A, 8B, and 9. Referring first to Fig. 6, a usual three-way valve construction (which may correspond to the valves Hi8, H6 and H2) is shown as comprising an enclosing housing I 30, provided with upper and lower inlet nipples I32 and I32, which receive threaded nipples I35 and I38. A tubular valve element I iil is secured in place between the nipples ISIS and I38, and is provided with an intermediate dividing wall I42, which divides it into two tubular portions Hi l and I46. A series of openings M8 is positioned immediately above the wall I42 and a similar series of openings I50 is positioned immediately therebelow. A valve element I52 is slidably fitted over the member Hi3, and is normally held in its illustrated upper position by a spring I54. In this upper position, the valve element closes oil the openings I48, but exposes the openings I50 to exhaust, through the housing I35. The valve element I52 is embraced by a forked operating lever I56. which engages in an annular recess I58 in the valve element. Lever I56 is pivoted to the housing at 569 and is disposed to be operated by the armature I 62, associated with th electro magnet I54. It will be understood that if the lever I56 is pivoted in a counterclockwise direction, it forces the valve element I52 downwardy against the force of the spring I54 and bridges the two series of openings hi3 and I50, thereby connecting the nipple I 36 to the nipple I38. When the electromagnet I54 is de-energized, however, the spring I54 is enabled to return the parts to the illustrated positions in which the nipple I 38 is connected to exhaust and the nipple I35 is closed oil". The four-way valve shown in Fig. 7 is similar to the above-described three-way construction, but comprises an inlet Iii] which communicates with the bore I72 in a stationarily mounted plug-I14. A tubular member I15, which may correspond to the previously described tubular member MILis-seated between the nipple I18 and the upper side of the plug. A similar tubular member I30 is seated between the lower surface of th plug and the lower nipple I82. The upper tubular member I16 is provided with a vertically slidable valve element I84 which corresponds to the previously described valve element and is similarly associated with the pivotally mounted operating arm I86. The lower tubular element is provided with a slidable valve element I88, which is like the valve element I84 except that it does not have the annular recess for cooperation with the arm I86. The valve elements I82 and 388 are interconnected by a sleeve I96, and so move as a unit. These elements are continuously urged to their illustrated upper positions by a compression spring I92. In the illustrated position, the upper valve element bridges the circumferentially disposed openings I34 and I96 associat d therewith, and thus connects the upper nipple I'I8 to the inlet I'II]. On the other hand, the lower valve element I83 is in its upper position in which it isolates its series of openings I98 from the companion series 282, thus closing off the nipple I82 from the inlet III In this position of the parts, also, the lower series of openings 20s is exposed so that the nipple I82 is connected to exhaust through the housing. If the electromagnet 252 is energized, on the other hand, the valve elements Ian and I38 are moved down wardly to positions in which the openings I94 and IE5 are isolated from each other, the openings I94 are exposed and so connect the nipple I13 to exhaust, and the openings I28 and 2% are bridged so as to connect the nipple 82 to the inlet I10.

The two-way hydraulic valve I22 is illustrated in Figs. 8, 8A and 8B as comprising an enclosing housing 2H1. which receives an electromagnet 2 I 2, armature 2M whereof is pivotally connected by levers 2I6 and 2I8 to a cam shaft 220, which projects into a valve body 222. The lever 2 I8 is continuously urged to the illustrated position by a torsion spring 224, in which position the cam carried by the pin 2251 enables the spring 225 to ho d the poppet type valve 228 in the closed position. If the electromagnet 2I2 is energized, on the other hand, pin 220 is rocked in a direction to force the valve 223 open against the force of the SOI'lIlg 226. It will be understood that the valve 2 I2 is so positioned in its associated line that the oil flows which are intended to be blocked by it act against the valve element 228 in a direction to hold it closed.

The remaining valve I 24 is diagrammatically shown in Fig. 9 as comprising a rectangular housing 240, which is dri11ed and plugged to provide a series of four passages 242, 244, 245 and 248, which afiord two parallel passages through the valve. The passage 242 receives a spring-pressed ball valve 258, which is normally held upon its seat 252 by a, spring 254. The passage 245 receives a ball valve 256 which is normally held on its seat 258 by a sprin 260. The valve I24 is interposed in the return line from the upper electrode cylinder 34 in the manner shown in Fig. 10, with the nipple 252 connected near the ram and the other nipple 252 connected away from the ram. The spring 254 is heavy enough to prevent a flow from the ram the passage 242 when the system is inactive, at which time the only pressure applied to this circuit is represented by the weight of the upper electrode structure, the piston and piston rod of the ram 34 and the weight of the oil which is beneath the piston of the ram 34. Such flow is 34 through the line 256 and and the housing of the valve H2,

answer" entirely prevented, of course, through the passage 246 by the valve 256. If, however, as described below, such pressure is exceeded, the valve 256 is removed from its seat, allowing a downwardv The air and oil circuits of the present system are shown diagrammatically in Fig. 10, and an electrical control system arranged to provide the proper sequence for the system of Fig. 10 is shown in Fig. 11. It is believed that the remaining details of the system may best be understood by a description of Figs. 10 and 11. Referring first to ,Fig. 10, air at a suitable pressure such, for example, as ninety pounds per square inch, is admitted through a, supply line 216 and through suitable strainer, filter andoiler elements 212 and 214, to a, line 216, from which branches 218 and 286 extend to the regulator valves H8 and I26 and the three-way control valve II2. Valve I26 is connected through lines 282 and 284 and the three-way control valve I I6, to thehigh pressure cylinder 66 of the booster I6. Similarly, valve H8 is connected through lines 286 and 268 and control valve I68, to the low pressure cylinder 96 associated with the booster.

The oil cylinder I66 of the booster is connected, through line 266 and branch lines 292 and 294, with the upper and lower ends, respectively, of the electrode rams 34 and 42, which branch lines include the regulator valves H4 and H6.

The branch line 294 is also connected to line 266 which is connected in turn to the cylinder 52 and includes the two-way valve I22.

The remaining cylinder 54 is connected through oil line 298 and branch lines 366 and 362 int the rams 34 and 42 at points below and above the pistons thereof, respectively. The branch line 366 includes the previously mentioned double check valve I24.

In the normal or inactive position of the machine, the piston of the ram 34 is elevated and the piston of the ram 42 is at its lower position. Under these conditions, check valve I24 prevents a flow out of the ram 34 through the line 266, and ram 34 and its associated electrode I6 are, consequently, maintained in their upper positions. The weight. of the lower electrode structure and the movable parts of ram 42, on the other hand, maintain these members in their lower positions. Cylinders 52 and 54 are normally filled, as aforesaid, with oil to approximately the level of the usual floats 55 and 51 therein, which levels are maintained equalized by the previously described equalizing valve 56. The oil lines extending between the cylinders 52 and54, the booster I6 and the rams 34 and 42 are, of course, filled with oil.

Under the conditions stated, further, valves H2 and W6 are de-energized so that, consequently, the air spaces above the oil in the cylinders 52 and 54 are connected to exhaust. The exhaust connection for the cylinder 52 is made directly through the housing of described above, whereas the exhaust connection for the cylinder 54 is made through the valve I66 Further, the valves I68 and H6 are in the d'e-energized condition, so that the cylinder spaces 66'and'96- of the ram I6, associated therewith, are connected to exhaust. At the same time, the hydraulic valve I22 isin its closedv position, in which it is effective to prevent a return flow of fluid from the lines,

the valve I66, as-

such as 296 and 292, into the cylinder 52. Such a return flow through the line 294 to the underside of the piston associated with the ram 42 is prevented by the weight of the moving parts associated therewith.

Assuming it is desired to effect a welding operation, the work may be positioned between the upper and lower electrodes I6 and I8 and, as aforesaid, the positioning of the work may be such that it'is unequally spaced from the two electrodes. To cause the electrodes to clamp the work, the valves H2, I66 and I22 may be simultaneously energized, as described in connection with Fig. 11. The energization of valve I22 completes the oil circuit from the cylinder 52 to the two' rams 64 and 42. The energization of valve H2 connects the air line 364 to the source 216. The energization of valve. I66 connects the air space above the oil in the cylinder 54 to exhaust and: connects the air space above the oil in cylinder52to line 564through line 366. The pressurethus built up'in cylinder 52 forces the equalizer valve 56 to the closed position and also causes a flow of Oilthrollgh lines 266, 292 and 294 to the rams 34 and 42. A similar pressure is applied'to line266, but'no movement of the booster I6 results therefrom, since the pistons thereof are at limit'positions. If any leakage has occurred to partially empty cylinder I66 during the idle periodlof the machine, such leakage is, of course, immediately replaced by the initial flow from cylinder 52. To accommodate any such leakage, a drain line 25H containing a usual checkvalve 363 may be connected between the cylinder 52 and engaging position. In most cases it is preferred to use an adjustment which causes the rams 34 and 42 to move at approximately the same rate. Assuming the spacing between the work and the respective electrodes is unequal, one or the other of the electrodes engages the work prior to its engagement by the other electrode. When such engagement occurs, a resistive pressure is applied to such engaging electrode which interrupts its further movement. The movement of the other electrode, however, continues until it engages the work and it will be understood that the initial engaging pressure of the electrodes against the work is determined by the unit pressure applied to the cylinder 52 through the line 366. During such downward and upward movements of the rams 34 and 42, respectively, oil is discharged from the under and upper sides of the pistcns thereof through lines 366, 362 and 268 into cylinder' 54. It will be understood that the pressure applied to ram 34 through the line 262 is effective, as aforesaid, to overcome the resistance of the valve I24 to such flow.

After the electrodes have engaged the work, the hydraulic valve I22 is de-energized, which action interrupts the hydraulic circuit between the cylinder 52 and the rams 34 and 42, thereby preventing an escape of oil from these rams and serving to maintain the electrodes in engagement with the work.

At the same time, or shortly after the valve I22 is ole-energized, the low pressure booster valve I08 is energized, connecting the low pressure cylinder 95 of the booster Hi to the source of air supply through the regulator valve H8. As soon as this action occurs, pressure is applied to the oil in the booster cylinder Hi through the pistons 86 and '58, which pressure is transmitted to the rams 34 and 42 through the lines 290, 292 and 294. This action immediately increases the pressure applied between the electrodes by an amount determinedby the boosting ratio of the booster ill.

The high pressure booster valve may be actuated at a desired stage of the welding operation, depending upon the character of the welding process employed. The electrical control system of Fig. 11 is one which is adapted to practice the process disclosed and claimed in the copending application of Leathers and Benkert, Serial No. 447,006, filed June 15, 1942, as a continuation of their earlier application, Serial No. 422,036, filed December 8, 1941. In this process, the welding cycle includes one or more successive stages, each stage being made up by a controlled heating eriod and. a controlled cooling period. With this process, it is preferred to employ the aforesaid lower welding pressure, as determined by valve Hi8, throughout the heating part of each stage, and to employ a higher or forging pressure, throughout the cooling part cfeach stage. Accordingly, with such process the energization of valve Hil is delayed for a suitable period after the energization of valve I 08. The energization of valve Hll connects the forging pressure cylinder space Sll of the ram l!) to the source of air supply through the regulator valve E23 and, consequently, increases the pressure applied between the electrodes by an amount determined by the pressure built up in such cylinder space.

In case the cycle includes a succession of stages, the valve llll may be energized and lie-energized a plurality of times, being energized at the beginning of the cooling part of each stag and being de-energized again at the beginning of the heating part of the following stage.

At the conclusion of the weld, the valves IE8 and I iii are de-energized. which relieves the forging and welding pressures on the electrodes and initiates a reduction in the pressure between them to the value initially determined by cylinder 52. At the same time, or very shortly thereafter, the four-way valve I26 is ole-energized and the hydraulic valve 122 is i e-energized, valve 322 being retained for the time being in the energized condition. The de-energization of valve Hi6 connects the air space in cylinder 52 to exhaust, and connects the air space in cylinder 54 to the source through valve H2. The consequent air pressure in cylinder 54 closes valve 55 in its opposite position and causes a return flow of oil therefrom to the rams 34 and 22, causing these rams to reassume their normal positions in which the electrodes are separated from the work. This return flow is accompanied by a return flow through lines 292 and 294, the now open valve 122 and line 295 to cylinder 52.

At the conclusion of the just-mentioned return movement of the electrodes, valves H2 and I22 are ole-energized. These actions again close off the line 295 and prevent a circulation of oil from the lines 2% and 292 into the cylinder 52 and also connect the air space in cylinder 54 to exhaust, thereby relieving the air pressure therein and en- -abling the equalizer valve 56 to equalize the oil levels in the two cylinders. The system is thus returned to its normal condition in readiness for another cycle.

In certain cases it is desirable to employ the present system withsone or the other of the electrodes retained in a stationary position. As shown in Fig. 10, a shut-off valve 3 l B is associated with the lower ram 42 and it will be understood that if this valve is closed, ram 42 remains continuously in its lower position, the only movable electrode being the upper electrode associated with ram 34.

t will be appreciated that in the broader aspects of the invention various dilferent control systems may be associated with the above described machine, it being preferred, as aforesaid, to use the machine to practice the process of the aforesaid copending application. Fig. 11 illustrates diagrammatically sufiicient circuits to afford an understanding of such operation. In Fig. 11 the electrodes 16 and I8 are shown as connected to the welding transformer 22 in the previously described manner and current flow to the electrodes is controlled by a pair of electric discharge devices RI and R2, which may be and preferably are of the type sold commercially under the trade-name Ignitrons, the operation whereof is well understood. The discharge devices-Pei and :R2 are provided with a conventional excitation circuit comprising auxiliary rectifiers 322 and 322 and the normally open contact CRila of a usual electromagnetic control relay. It will be understood that so long as contact Child is open, the devices RI and R2 are nonconductive and that, consequently, no current is supplied to the welding transformer 22.

Cooperating with relay CR9 is a similar series of usual electromagnetic relays CRI through CR8, the contacts whereof bear similar designations with the postscripts a, 1), etc. The system further includes a series of usual three-element electronic valves VI, V2, V3 and V4, all of which may be and preferably are of the high vacuum or continuous control type. The system further includes a pyrometer unit which is described in detail in the aforesaid copending application and is shown diagrammatically only in Fig. 11. The unit is designated PY and is provided with a single contact PYa, which is open so long as the thermoelectric potential applied between the in put leads 324 and 326 is below a predetermined value.v These contacts close when, and remain closed so long as, this potential exceeds the justmentioned value. The thermoelectric potential is developed between the leads 324 and 326 by forming a thermocouple between the electrode l6 and a suitable element 328 embedded therein, all as described in said copending application. Cooperating with the pyrometer is a ratcheting unit 336, which may be of a conventional type and is diagrammatically shown. This ratcheting unit is provided with a series of movable arms 332, 534 and 336, which cooperate with series of associated contacts to adjust the heat setting of the pyrometer, to control the application to and removal of the forging pressure and to efiect the resetting of the system at the conclusion of a welding operation. The initiation of a Welding operation is under the control of a two-stage switch, shown as made up of two separately operable push buttons Pl and P2.

It is believed the remaining details of the systern may best be understood by a description of the operationthereof.

To place the system in condition for operation, the illustrative disconnect switches LS! and LS2 lay CB3.

may be closed, thereby connecting the supply conductors Li and L2 to a suitable source of alternating current. Energization of the line conductors Ll and L2 is without immediate effect other than to complete circuits for transformers T3, T and Ti i, associated with the d circuits of valves Vl, V2 and V4. Upon being energized,

these transformers apply blocking potentials to the grids of these valves, thereby'preventing current flow therethrough, and also charge up the grid control condensers Cl, C2 and C5, associated therewith.

To initiate a welding operation, the first-stage switch Pl may be closed, which action eifects the previously desoribedoperations of bringing the electrodes into engagement with the work at a pressure determined by the pressurein th cylinder 52 (Fig. More particularly, closure of switch Pl completes obvious energizing circuits in parallel for valves H2, 122 and IE5, and for transformers Tl and'TLassociated'with the anode and grid circuits of valve VI. The .circuit for transformer Tl includes the now closed back contacts CRla of control relay CR1, the circuit easement with'the work.

The energization :of transformer T2 opposes the originally energized transformer T3 and enables the energ originally stored in the grid control condenser Cl to discharge through the indicated local circuit, including resistor 340. At the expiration of a discharge period determined by the characteristics of this circuit, valve VI becomes conductive and enables the now energized transformer TI' to passcurrenttherethrough and energize controlrelayCRZ. This action causes this relay to close its normally open contacts CRrla, CR2c, and CRZcZ and to-open its back contact 0321). The latter action tie-energizes the two-way hydraulic valve 122, thereby, as afore- SalQ,'l T3ppiI -g sufiieient oil in the electrode rams es and 32 to maintain the electrodes in engagemerit with-the work with the desired preliminary pressure. It will be understood, accordinglsh'that the-timingafiorded by condenser Cl is sufficient to allow for the full travel of the electrodes from their retracted positions to their work engaging positions. The closure ofcontact CRZa is without effect in the operation now being described, since it is assumed that the switch Pi is still closed. Closure of contact CR-2dserves only to prepare a circuit for control relay CR1.

Closure of contact CRZc completes obvious energizing circuits for transformers T4 and T5, associated-with the anode and grid circuits of valve V2. Upon being energized, transformer T5 opposes the originally energized transformer T6 and enables the energy originally stored in the associated condenser C2 to discharge through the local circuit including resistor 3&2. At the com clusion of a relatively short discharge period determined by the characteristics of this circuit, valve V2 becomes conductive and enables the now energized'transformer T4 to energize control re-. This action causes this relay to close its normally open contacts CRSa, CRSc and CHM and to .open' its back contact 03131). The latter action is without effect since the now closed contacts Cl-c311 and (IBM complete parallel circuits which retain the valve l 12 energized. The closure of contact CRoc prepares circuits for the welding pressure control valve lfil? and for the plate transformer Tl, associated with valve V3 and control relay CR6, which circuits, however, remain incomplete, since the second-stage starting switch P2 is still open. So long, therefore, as switch Pi is retained closed, the electrodes Hi and it remain in-engagement with the work with the preliminary contact pressure. Closure of contact C3311 is without effect other than to further condition the circuit for control relay CR1.

To actually initiate the weld. the second-stage switch P2 may be closed and this action may be I caused to take place substantially simultaneously with the closure of switch Pl or after an interval thereafter. If the closure of switch P2 takes place substantially simultaneously with the closure or switch Pl, the actuation of the welding pressure relay i538 and the just-mentioned transformer Tl is, nevertheless, delayed long enough to allow for the movement of the electrodes into engagement with the work, which time interval is afforded by the delay in the closing movement of the lastrnentioned relay contact CR'Bc, This latter delay, as aforesaid, is controlled by condenser C2.

The closure of switch P2 completes an obvious energizing circuit for the winding of control relay CRi, which thereupon closes its normally open contacts CRia, CPA!) and CRlc. Closure of contacts CRM and CRlb completes self-holding cir cuits in parallel with the switches Pi and P2, which may thereupon be released to the open position without interrupting the welding cycle. The closure of switch P2 and of contact CRib also completes the previously traced circuit for the welding pressure valve lllil, which thereupon operates, as described with reference to Fig. 15, to apply the normal or welding pressure to the electrodes i l and it. The effect of contact CRic is described below.

The circuit for transformer T1 is completed simultaneously with the completion of the circuit for valve lat. 'Upon'being energized, transformer Tl applies potential to valve V55. Under the conditions stated, valve V3 is conductive transformer Tl is, consequently, enabled to energize controlrelay C l. Upon being energized, control relay C4 closes its normally open contact CR la, thereby energizing the welding controlr lay CR8. Upon being energized, relay CR9 closes its sole contact Chats and aotuates the power contactor represented by the reversely connected main rectifiers R5 and R2. This action, as will be understood, initiates the flow of welding current to the work.

Closure of contact CRa also energizes the grid transformer T8, associated with valve V3, and enables it to apply a blocking potential to valve V3, This action interrupts the supply or" energizing current to control relay CR l, whereupon the energy stored in the winding thereof starts to discharge through the associated condenser CG. At the expiration of a so-called heat period following this action control relay CRQ resumes its original tie-energized position and opens contact'CR ic. This action ole-energizes the welding relay CR3, which thereupon interrupts further fiow of welding current. to the work. The opening of contact CR la also enables the energy stored in condenser C3 to start discharging through the associated local circuit including-resistor ass, and at the expiration of a cool period, valve V3 again becomes conductive, enabling transformer T1 to re-energize relay CR4. This re-energization again initiates the flow of weldin current, as before, and also applies a blocking potential to valve V3. Control relay CR6 therefore nulsates between the energized and de-energized conditions, current being supplied to the Welding circuit so long as relay CR4 is energized, and being in terrupted so long as relay CR4 is ole-energized. It will be understood that the heat and cool intervals are adjustable in length and are proportioned to suit the Work being welded.

Reverting to the energization of control relay .CRl, closure of contact CRlc thereof completes a circuit through the now closed back contacts CREZ) and CR ib of relays CR5 and CR3, respectively, to thereby connect the operating winding 366 of the ratchet unit sec to a. suitable source of direct current illustrated as a battery 343. Upon being energized, winding 346 operates its armature and causes the ratchet unit to advance one notch from its initial or starting position to its first operating position in which the arms 33 334 and 335 are in engagement, respectively, with. terminals at, hi and cl. In the sequence now being described, terminals bi and cl are idle, but terminal al adjusts the pyrometer PY to respond to a temperature corresponding to the critical welding temperature of the work.

The current supplied to the work during the successive heat periods gradually elevates the temperature of the work, and when critical temperature is reached, a weld nugget is formed between the two workpieces. When this tempera ture is attained, the thermoelectric potential between the pyrometer leads 32 i and 323 is sufficient h to cause this element to close its sole contact PYa. Closure of contact PYa completes obvious energizing circuits in parallel with each other for control relay CR6 and for transformers T9 and Tit, associated with the anode and grid circuits of valve VG. Upon being energized, relay CR i closes its contact CRfia and opens its contact CRBb. The latter action interrupts the previously traced circuit for the operating winding 3 56 of the ratchet unit, which action does not advance the ratchet unit but does allow a return move .ment of the armature to a position in which it engages the next successive tooth of the ratchet member. Upon being energized, transformer Tit! opposes transformer Til and enables stored in condenser Ct to start discharging through the local circuit including resistor At the expiration of a short discharge period just sufllciently long to allow. the above mentioned re turn movement of the armature associated with the ratchet operating Winding 3%, valve V-i becomes conductive and enables transformer T9 to energize control relay CR5.

Upon being energized, relay CR5 closes its contact CRlia and opens its contact CRSb. The former action completes a circuit through the now closed contacts CRlc and CR ia for the operating winding 346, which thereupon moves the .ratchet unit 330 to its second operating position in which the arms 332, 33 and 336 are in engagement with terminals a2, b2 and c2, respectlvely. Terminal 02 is an idle terminal in the sequence now being described, but the movement of arm 332 onto terminal a2 readjusts the py rometersetting to a relatively low temperature corresponding, for example, to a temperature well below the annealing temperature of the work. As described in the aforesaid copending application, the'pyrometer is sluggish enough in its 'action to retain the contact PYa closed during the the energy with terminal b2 completes an obvious energizing circuit for the winding of control winding CR8, which thereupon closes its sole contact CRta and completes an energizing circuit for the high pressure or forging valve i It. Upon being energized, as described in connection with Fig. 10, valve I it] increases the electrode pressure to the maximum or forging value.

The above-mentioned energization of control relay CR5 also causes its contact CRiic to open, which action immediately de-energizes transformer T1 and the welding current relay CR8. The de-energization of the welding current relay CR9 interrupts further flow of welding current to the work and it will be understood, therefore, that the attainment of the welding temperature in the work results in the interruption of the flow of welding current and further results in the application to the work of the higher or forging pressure.

The de-energization of transformer T1 also causes relay CR4 to resume the de-energized condition after the timing out of condenser C6, as aforesaid. This action is without effect in the sequence being described in view of the fact that control relay CR9 is now in the de-energized condition. It will be noted that if the energization of control relay CR5 takes place during a cool period between successive pulsating flows of welding current, such action serves merely to prevent the re-energization of relay CR4 and CR9 at the expiration of the cool period in question.

When the work temperature falls to the aforesaid relatively low value, at which temperature the weld may be expected to have solidly set, so that the electrode pressure may be relieved, the pyrometer PY releases its contacts PYa to the open position. This action immediately deenergizes control relay CR5 and transformers T9 and Till. The deenergization of control relay CR6 causes its contact CRBa to reopen and its contact CR6b to reclose. The latter action is without effect, since contact CR5b is still open, but the former action again interrupts the cir cuit for the ratchet operating winding 345. This action does not cause an advancing movement of the ratchet unit, but it does allow the armature of winding 346 to be withdrawn to a position in which it engages the next successive ratchet tooth.

The de-energization of transformer TH} enables transformer Tll to again apply a blocking potential to the grid of valve Vt. This action coupled with the de-energization of transformer T5; interrupts the supply of energizing current for the winding of relay CR5 and enables the energy stored in the winding thereof to start discharging through the associated condenser (3?. After a short period of the order, for example, of several cycles of the source, relay CR5 resumes the deencrgized position. This interval is long enough, as will be understood, to enable the just-mentioned return movement of the armature associated with the ratchet operating winding 34B.

Upon being ole-energized, relay CR5 opens its 15 contact CREa, without eiiect, and also recloses its contact CREb. This action re-energizes the ratchet operating winding 346 and enables it to advance the ratchet unit to its. third position in which the arm 336 engages the terminal 03. This action also moves the arms 332 and 3% out of engagement with their terminals a2 and b2. The former action is without effect, since the pyrometer contact PYa is already open, but the latter action interrupts the circuit for the .high pressure control relay-CR8. Upon being so de-energized, control relay CR8 interrupts the circuit for the high pressure valve 1 Ill which, as describedin connection with Fig. 10, thereupon acts to relieve.

the high or forging pressure'from the electrodes.

The engagement of arm 33% with terminal c3 completes a circuit for the winding of control relay CR1, (through now closed contacts CRM and CRM) which thereupon opens its contact CHM and closes its contacts CR'lb and CRlc..

Contact CRlb completes a circuit for the reset winding 352, associated with the ratchet unit are, which thereupon withdraws its armature from engagement with the ratchet teeth and enables 'the return spring 355 to restore the is opened thereby, which action interrupts the circuit for the reset winding 352.

During the return movement of the ratchet unit, the arm 332 sweeps over the terminals a2 and al, which action is, however, without effect, since the work is now at a temperature below the temperatures at which these terminals respond. During this return movement, also, the arm 3% sweeps over the terminal b2, but the period of this energization is too short to enable relay CR8 to become re-energized. If desired and as shown, a delaying condenser 356 may be connected in parallel with the winding of relay CR8.

The return movementof the arm 33% interrupts the original circuit for relay CR1. Closure of contact CRlc, however, completes a self-holding circuit for relay CR1, so that such movement of arm 33% is without effect.

As to resetting actions,-the opening of contact CR'la directly interrupts the energizing circuits for control relay CR5, transformer Tl, transformer T? and control relay CR9. It is noted that the de-energization of relay CR at the conclusion of the coolin down of the work also caused its contact C1250 to reclose, which action tends to recomplete the circuit for transformer Tl and for control relay CR9. The de-energization of relay CR5, however, and as aforesaid, also causes the energization of relay CR1, which, at contact CRla, prevents recompletion of these circuits. In practice, it is found that, in view of the relatively heavier character of at least control relay CR9, contact CRia takes efiect before relay CBS is re-energized. Thus, contact CREic, in reclosing, is ineiiective to re-initiate a flow of welding cur-rent to the work. If desired, of course, such proper sequencing can be further inv sured by interposing a slight delay in the closing movement of contact .CRfic, so as to cause the closing of this contact to lag behind the reclosure of contact CREE).

Continuing with the resetting action, the deenergization of relay CRl causes its contacts CRla, CRlb and CRlc to reopen. The latter contact lie-energizes the operating winding 3416 of the ing its Contact cast.

ratchet unit. Contact CHM and contact GR), in opening, further interrupt the circuit for transformer Ti and also interrupt the previously traced holding circuit in parallel with the pilot switches Pi and P2. In addition, the opening of contact CRih interrupts the circuit for the welding pressure valve Hi8, which thereupon, as described in connection with Fig. 10, relieves the welding pressure from the work and restores this pressure to the initial low value.

The opening of contacts CRIa and CRlb also interrupts the remaining energizing circuit for the winding of the four-way valve its, associated with the two cylinders 52 and 54, thereby connecting cylinder 52 to exhaust and connecting the return cylinder 5% to the source of air Pressure. This action is preparatory to the return or separating movements of'the electrodes.

The de-energization of transformer TI de-energizes control relay CR2, which thereupon resumes the de-energized condition, opening its contacts CR2a, CRZc and CRZd and closing its contact CRZb. The opening of contacts CHM and CRZd is without immediate efiect, but the closure of contact CR2!) recompletes a circuit for the two-way hydraulic valve i222, which thereupon functions, as described in connection with Fig. 10, to enable the separating movements of the electrodes under the influence of the air pressure now applied to cylinder 54.

The opening of contact CRZc interrupts the circuits for transformers T6 and T5, associated with valve V2, and control relay CR3. These actions cooperate to interrupt the further How of energizing current to control relay CR3, whereupon the energy stored in the coil thereof starts to discharge through the associated condenser 05. At the expiration of a relatively short period, sufiiciently long to enable the full separating movement of the electrodes to take place, relay CR3 resumes the ale-energized position, opening its contacts CRZ-la, CR3c and CR3d, and reclos- The opening of contact C330 and the closure or contacts CR3b are without efiect, since the associated circuits areopen at other points. The opening of'contact CR3a interrupts the only remaining energizing circuits for valves H2 and [22. Upon being de-energized, valve 522 closes= off the line 296, as aforesaid, and valve H2 relieves the air pressure applied to cylinder '54 through the now tie-energized valve lilii. The opening of contact CR3d interrupts the previously traced holding circuit for relay CRE, which thereupon resumes the deenergized position without efi'ect. These resetting operations, therefore, serve to restore the system to its normal condition, in readiness for the next welding operation.

In certain cases it is found necessary, after initially moving the electrodes into engagement with the work, to again separate them'beiore initiating the actual welding operation. 'Such an action can readily be accomplished by closing pilot switch Pl, without closing pilot switch P2, and by thereafter releasing pilot switch Pl. It will be recalled from previous description that closure of pilot sWitch'Pl first energizes valves H2, 522 and N36 to thereby cause the electrodes to start towards the work engaging positions.

Also, by causing the energization of relays CR2 and CR3, pilot switch Pl causes the two-way hydraulic valve I22 to be tie-energized after the electrodes engage the work. It will further be recalled that so long asswitch PI is held closed (assuming switch P2 is maintained in the open 17 position), valves H2 and H36 and relays CR2 and CR3 remain energized, and the electrodes engage the work with the relatively light preliminary pressure.

If, under these conditions, switch Pi is reopened, such action immediately de-energizes the four-way valve I06 and also immediately de-energizes transformers TI and T2. The de-energization of the four-way valve Hit applies air to the cylinder 54, preparatory to the return movement of the electrodes, as aforesaid. The deenergization of transformers Ti and T2 causes relay CR2 to be de-energized. This action causes contact CRZa to reopen and contact CRZb to reclose. The former action is without efiect, since contact CR3a is still closed, but the latter action recompletes the circuit for the two-way hydraulic valve I22, which thereupon reopens and enables the return movements of the electrodes, as previously described.

The de-energizaticn of relay CR2 also opens its contact CRZc which, as described in connection with the usual resetting operation, results in the de-energization of relay CR3. This latter de-energization occurs at the end of a period suflic-ient to allow the full separating movement of the electrodes. When relay CR3 resumes the de-energized position, it completes the resetting action, in the previously described manner, by de-energizing the remaining valves 1 l2 and I22.

As described above, the control system of Fig. 11 provides only a single heating stage and a single cooling stage. It will be understood that,

if desired, the indexing unit may be provided with additional terminals, as indicated, so that as described in the aforesaid Leathers and Benkert application, a succession of heating and cooling stages are provided. In such case, it will be understood that the high pressure relay CR8 may be energized during each cooling stage and it will also be understood that the actuation of the resetting relay CRT is delayed until the end of the final cooling stage. It is thought, however, that the single stage system specifically described above serves to illustrate the operation of the present invention.

Although only a single specific embodiment of the invention has been described in detail, it will be appreciated that various modifications in the form, number and arrangement of the parts may be made without departing from the spirit and scope of the present invention.

What is claimed is:

1. A welding machine having a pair of opposed electrodes, each movable between a retracted position and a work engaging position, means including motive means individual to each electrode for moving them between said positions, a source of power common to said motive means for effecting a said movement to the work engaging position, said source of power including means constructed and arranged to enable the source to continue to move one electrode independently of continued movement of the other electrode, and means for actuating said motive means to retract the electrodes to the retracted positions thereof.

2. A welding machine having an electrode movable between a retracted position and a work engaging position, a hydraulically operated motor for effecting a said movement of said electrode, a reservoir disposed to be in communication with said motor, means for applying an elastic fluid pressure to fluid contained in said reservoir to cause a deliver of such fluid from the reservoir to the motor, and supplemental means operative to increase the hydraulic pressure in said motor after said electrode has reached the work engaging position, said supplemental means including a conduit communicating with the motor and containing hydraulic fluid, piston means for transmitting pressure through the conduit to the motor, and control means for applying an elastic fluid pressure to the piston.

3. In a welding machine, the combination of a work engaging part movable between a retracted position and a work engaging position, a first motive means for eilecting a said movement, a second motive means for applying a working pressure to said part while in the work engaging position, and control means for said motive means selectively operable to either actuate only said first-mentioned motive means or to operate both said first and second motive means in sequential relation, and timing means responsive to said control means for interposing a predetermined time delay between the operation of said first and second means.

4. The structure of claim 3 wherein said part is provided with a fluid motor, and said first and second motive means comprise means for supplying said motor with fluid pressure.

5. The structure of claim 3 wherein said part is provided with a fluid motor, wherein said first and second motive mean comprise means for supplying said motor with fluid pressure, and wherein means are provided to render the first motive means inefiective while the second motive means is efiective.

6. The structure of claim 2 including means operative to prevent a flow of fluid from said motor to said reservoir when said control means is actuated.

HUGO PURAT. 

